US20100323542A1 - Electrical connector - Google Patents
Electrical connector Download PDFInfo
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- US20100323542A1 US20100323542A1 US12/817,491 US81749110A US2010323542A1 US 20100323542 A1 US20100323542 A1 US 20100323542A1 US 81749110 A US81749110 A US 81749110A US 2010323542 A1 US2010323542 A1 US 2010323542A1
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- Prior art keywords
- connector
- cover
- housing
- contact
- electrical
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
- H01R13/62—Means for facilitating engagement or disengagement of coupling parts or for holding them in engagement
- H01R13/625—Casing or ring with bayonet engagement
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
- H01R13/44—Means for preventing access to live contacts
- H01R13/447—Shutter or cover plate
- H01R13/453—Shutter or cover plate opened by engagement of counterpart
- H01R13/4532—Rotating shutter
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
- H01R13/46—Bases; Cases
- H01R13/53—Bases or cases for heavy duty; Bases or cases for high voltage with means for preventing corona or arcing
Definitions
- Electrical connectors are used to connect electrical devices to power sources or to join electrical circuits. Electrical connectors generally operate by connecting ground and power terminals of respective connector elements together in a manner that facilitates electrical continuity between the respective elements. In some embodiments, for example, a male connector may be inserted into a corresponding female connector to effect the connection.
- connectors in such high voltage or hazardous environments should apply power in a manner that will not damage equipment, and in a manner that provides a safe environment for users.
- FIG. 1 is an isometric view of an exemplary embodiment of a electrical connector consistent with implementations described herein;
- FIG. 2 is a cross-sectional view of the connector of FIG. 1 in a connected configuration
- FIG. 3 is an enlarged, cross-sectional isometric view of the first housing and contact assembly of FIG. 1 ;
- FIGS. 4A-4E are cross-sectional diagrams illustrating exemplary implementations of the connector of FIG. 1 ;
- FIGS. 5A-5C are cross-sectional diagrams illustrating additional exemplary implementations of the connector of FIG. 1 ;
- FIGS. 6A-6D are isometric illustrations of the connector of FIG. 1 in various stages of connection.
- FIGS. 7A and 7B are isometric illustrations of the exemplary connector of FIG. 1 in various stages of disconnection.
- an electrical connector may be provided that minimizes deleterious effects associated with high voltage implementations and/or hazardous environment conditions.
- an electrical connector may include a male connector and a female connector, with the male connector configured for insertion into the female connector.
- the female connector may include an access assembly configured to prevent unintentional or undesired access to a contact assembly of the female connector.
- conductors in the male connector first bypass a dead front and proceed axially along the female connector to the contact assembly without electrically contacting the conductors in the contact assembly.
- the connector may be placed into a first connected position in which the male connector is securely attached to the female connector, but with the conductors of the male connector not electrically coupled to the female connector. This may be referred to as the connected—OFF position. Additional movement of the female connector and the male connector may bring the conductors into electrical contact and may place the connector into a second connected position, referred to as the connected—ON position.
- FIG. 1 is an exploded isometric diagram illustrating an exemplary electrical connector 100 consistent with embodiments described herein.
- FIG. 2 is a cross-section diagram of connector 100 taken in an axial direction.
- electrical connector 100 may include a female connector 102 and a male connector 104 .
- Female connector 102 may further include a first housing portion 106 , an intermediate housing portion 108 , a dead front 110 , a dead front spring 112 , a dead front pin 114 , first notched slots 116 , a contact assembly 118 , guide pins 120 , a center contact sleeve 122 , spring 124 , cup-connectors 126 , contacts 128 , and female cover 130 .
- Male connector 104 may include a second housing portion 132 , second notched slots 134 , a center connector pin 136 , connector pins 138 , and a male cover 140 .
- connector 100 may include a configuration that provides an insulating and reduced atmospheric environment between male and female contacts at the time of contact connection.
- male connector 104 may include second housing 132 , center connector pin 136 and connector pins 138 .
- center connector pin 136 may be configured for insertion into a central hole through the components of female connector 102 .
- center connector pin 136 may be configured to carry ground or common electrical signals/current.
- Connector pins 138 may be configured to carry current or electrical signals, such as current for high voltage electrical applications.
- Connector pins 138 as described more fully below, may be configured for insertion through dead front 110 , intermediate housing 108 , and first housing 106 .
- connector pins 138 may be configured for insertion into cup-connectors 126 .
- Second housing 132 of male connector 104 may include notched slots 134 configured to receive guide pins 120 connected to first housing 106 . Travel of guide pins through notched slots 134 may guide rotational and axial movement of female connector 102 relative to male connector 104 in a predetermined manner, as will be described in additional detail below.
- Male cover 140 may be formed over second housing 132 and may form a protective covering for male connector 104 as well as approximately one half of an enclosed environment for connector 100 upon connection to female connector 102 .
- Female connector 102 may include first housing 106 , intermediate housing 108 , and dead front 110 .
- first housing 106 , intermediate housing 108 , and dead front 110 may be substantially cylindrical and may be configured to reside within female cover 130 in a substantially nested manner. More specifically, first housing 106 may include a cavity therein for receiving intermediate housing 108 and dead front 110 .
- first housing 106 , intermediate housing 108 , and dead front 110 may be configured such that a cylindrical gap 200 is provided between an outer diameter of intermediate housing 108 /dead front 110 and an inner diameter of first housing 106 when intermediate housing 108 /dead front 110 is mounted axially within intermediate housing 106 .
- Gap 200 may be of a width suitable for receiving second housing 132 of male connector 104 during connection of connector 100 .
- Dead front 110 may be connected axially to intermediate housing 108 via dead front pin 114 .
- dead front 110 may include a flanged/notched configuration that engages a corresponding notched portion of intermediate housing 108 such that rotation of dead front 110 about dead front pin 114 is enabled within a predetermined range of motion.
- intermediate housing 108 and dead front 110 may be further configured to include holes 109 and 111 , respectively, corresponding to a spacing of connector pins 138 in male connector 104 .
- dead front 110 may be spring-loaded with respect to intermediate housing 108 , such that the holes in dead front 110 are not initially aligned with the holes in intermediate housing 108 .
- a central portion of intermediate housing 108 and dead front 110 may be recessed to receive dead front spring 112 .
- the biasing force provided by dead front spring 112 may urge dead front 110 into a first position relative to intermediate housing 108 .
- Rotation of dead front 110 about dead front pin 114 may oppose the biasing force of dead front spring 112 and may cause holes 111 in dead front 110 to align with holes 109 in intermediate housing 108 .
- Dead front 110 may operate to prevent an unintended or rushed connection of male connector 104 to female connector 102 in that a user must first insert connector pins 138 into dead front 110 , rotate dead front 110 relative to intermediate housing 108 until holes 109 align with holes 111 , and insert connector pins 138 further into intermediate housing 108 .
- first housing 106 , intermediate housing 108 , and holes 109 are configured to allow potentially combustible or hot gases to vent away from contact assembly 118 during insertion or removal of connector pins 138 into female connector 102 .
- holes 109 (and/or holes 111 ) may be filled with a conductive brush material or other assembly for increasing an efficiency of a potential flame path, in the event of an explosion in connector 100 . Additional details relating to the flame path provided in connector 100 are described below in relation to FIGS. 4A-4E and 5 A- 5 C.
- First housing 106 may be configured to support or otherwise connect to contact assembly 118 .
- FIG. 3 is an enlarged isometric view illustrating first housing 106 , contact assembly 118 , center contact sleeve 122 , and cup-connectors 126 .
- first housing 106 may be configured to include cavity 300 for receiving intermediate housing 108 therein, and contact openings 310 and center spring opening 320 therein which engagingly support cup-connectors 126 and center spring 124 , respectively.
- Contact openings 310 may be further configured to include axial grooves to receive connector pins 138 in a first non-connected position. Rotation of connector pins 138 relative to cup-connectors 126 may cause connector pins 138 to move within contact openings 310 and engage with cup-connectors 126 .
- center sleeve opening 320 and contact openings 310 may be configured to have a minimal volume for containing environmental air and exhaust gases.
- center sleeve opening 320 may be configured to closely conform to an outside diameter of center contact sleeve 122 .
- contact openings 310 may be configured to closely conform in size to cup-connectors 126 and an outside diameter of connector pins 138 .
- a total volume of space within center spring opening 320 and contact openings 310 is less than or equal to approximately 10 milliliters (ml).
- cup-connectors 126 may be formed of a resilient, conductive material, having a compressed C-shape as indicated by pinched portion 330 , in which an open end of cup-connectors 126 is slightly narrower than a width of connector pins 138 .
- the configuration of cup-connectors 126 may provide a snap-engagement with connector pins 138 upon rotational engagement between cup-connectors 126 and connector pins 138 .
- the compressed C-shape of cup-connectors 126 allows for a build up of potential energy as connector pins 138 traverse and slightly deform the “arms” of cup-connectors 126 and travel toward pinched portion 330 from within the base of cup connectors 126 .
- the built up potential energy may be released by projecting connector pins 138 out of and away from cup-connectors 126 , thus providing a snap disconnect releasing connector pins 138 from cup-connectors 126 .
- the speed in which a connection may be disengaged (or engaged) is significantly increased over non-snap-engagement implementations. This speed increase further reduces a likelihood of arcing or flashover during connection or disconnection of connector 100 .
- Center contact sleeve 122 may be configured to receive center connector pin 136 . Additionally, spring 124 may be positioned about center contact sleeve 122 within center spring opening 320 , such that the biasing force of spring 124 urges first housing 106 axially away from intermediate housing 108 . As discussed above, the volume of center spring opening 320 as well as contact openings 310 may be reduced to minimize the likelihood that an explosion will occur or the severity of an explosion in the event of arcing or flashover between connector pins 138 and cup-connectors 126 .
- Contacts 128 may be connected to cup-connectors 126 and center contact sleeve 122 . Each contact 128 may be further configured to receive wires or leads that extend through female cover 130 . As illustrated in FIG. 2 , male connector 104 may include similar contacts.
- first housing 106 may be further configured to include guide pins 120 .
- Guide pins 120 may be positioned such that the inwardly extending ends of guide pins 120 are received within first notched slots 116 in intermediate housing 108 .
- intermediate housing 108 may be inserted into first housing 106 prior to insertion of guide pins 120 into corresponding holes in first housing 106 .
- first notched slots 116 may be configured to enable both rotational and axial movement of intermediate housing 108 relative to first housing 106 within a predetermined range of motion.
- intermediate housing 108 may be configured to include a notched slot 116 allowing two stages of rotational movement, and one stage of axial movement.
- Second housing 132 in male connector 104 may be configured to include a similar notched slot 134 .
- rotational and axial movement of guide pins 120 within slot 116 may facilitate connection of female connector 102 to male connector 104 in two distinct positions.
- female connector 102 may be connected to male connector 104
- connector pins 138 are not electrically coupled to cup-connectors 126 . This may be referred to as the connected—OFF position.
- connector pins 138 may be moved into electrical engagement with cup-connectors 126 . This may be referred to as the connected—ON position.
- the shape of cup-connectors 126 may effectively secure connector pins 138 within cup-connectors 126 upon movement of connectors 102 and 104 from the first position to the second position.
- second housing 132 may become inserted in the gap formed between intermediate housing 108 and first housing 106 .
- Connector 100 may be further configured such that guide pins 120 restrain relative movement between first housing 106 , intermediate housing 108 , and second housing 132 . Because contact assembly 118 is fixed relative to first housing 106 and connector pins 138 are fixed relative to second housing 132 , rotation between first housing 106 and second housing 132 effectively brings connector pins 138 into electrical contact with cup-connectors 126 .
- female cover 130 and male cover 140 may form a contained environment sufficient to minimize an exposure to potentially volatile environmental conditions prior to electrical contact or proximity between connector pins 138 and cup-connectors 126 .
- interaction of components within connector 100 may provide a flame path for venting of a flame or explosion in the event of an explosion within connector 100 .
- elements of intermediate housing 108 , female cover 130 , and/or male cover 140 may be configured to provide for the venting or extinguishing of any such flame without destroying connector 100 or damaging the surrounding environment or personnel.
- spring 124 may provide an opposing force between guide pins 120 affixed to first housing 106 and notched slots 116 in intermediate housing 108 . This biasing force may be suitable for preventing or minimizing unintended movement of guide pins 120 relative to notched slots 116 through the positioning and size of the notches in notched slots 116 .
- Female cover 130 may be formed over first housing 106 and may form a protective covering for female connector 104 as well as approximately one half of the enclosed environment for connector 100 upon connection to male connector 102 .
- female cover 130 and/or male cover 140 may be formed of a plastic, rubber, or elastomeric material that provides both a high friction, easily grippable surface, in additional to protective insulative properties.
- female cover 130 and male cover 140 may include a textured or ridges surface to further enhance secure handling and connection of connector 100 .
- FIGS. 4A-4E are cross-sectional diagrams illustrating exemplary implementations of the connector 100 .
- an explosion or spark 400 at an interface between connector pin 138 and cup-connector 126 may travel along a flame path 410 provided for in connector 100 .
- flame path 400 may include interfacing surfaces between first housing 106 and intermediate housing 108 ⁇ circle around (1) ⁇ , interfacing surfaces between second housing 132 and first housing 106 ⁇ circle around (2) ⁇ , and interfacing surfaces between first housing 106 and male cover 140 ⁇ circle around (3) ⁇ .
- an explosion or spark may travel along flame path 410 and may vent from connector 100 at the interface between male cover 140 and female cover 130 .
- connector 100 may be capable of operating safely in hazardous environments.
- FIG. 4B illustrates another exemplary implementation of the interface between male cover 140 , female cover 130 , and first housing 106 .
- a gap 415 may be provided between male cover 140 and female cover 130 .
- Gap 415 may be suitably sized to efficiently enable release of explosive energy or flames from flame path 410 in the event of arcing or flashover within connector 100 , as described above in relation to FIG. 4A .
- FIGS. 4C and 4D illustrates another exemplary implementation of the interface between male cover 140 , female cover 130 , and first housing 106 .
- a male cover 140 may be provided with a hinged portion 420 or flap proximate to the interface with female cover 130 .
- hinged portion 420 may open or deform to allow the explosive energy, flames, and/or hot gases to exhaust from connector 100 .
- hinged portion may also be provided in female cover 140 , or in both male cover 140 and female cover 130 .
- FIG. 4E illustrates yet another exemplary implementation of the interface between male cover 140 , female cover 130 , and first housing 106 .
- male cover 140 and female cover 130 may be configured to overlap.
- male cover 140 may be provided with an enlarged portion 425 configured to receive female cover 130 in an overlapping manner.
- female cover 130 may be configured to interlock with enlarged portion 425 to further secure female connector 102 to male connector 104 during connection.
- flame path 410 may continue along the interface between enlarged portion 420 and female connector 130 to allow the explosive energy, flames, and/or hot gases to exhaust from connector 100 .
- Enlarged portion 425 may be suitably sized to efficiently enable release of explosive energy or flames from flame path 410 in the event of arcing or flashover within connector 100 .
- FIGS. 5A-5C are cross-sectional diagrams illustrating additional exemplary implementations of connector 100 .
- intermediate housing 108 may include one or more expansion chambers 500 for receiving explosive energy resulting from an explosion or spark experienced at an interface between connector pin 138 and cup-connector.
- each interface between a connector pin 138 and a cup-connector 126 may be connected to a respective expansion chamber 500 , e.g., via conductor opening 310 .
- expansion chambers 500 may include a resilient and/or compressible material 510 configured to compress and absorb explosive energy in the event of an explosion or spark. Compression of material 510 also opens up a volume of expansions chamber 500 thereby allowing explosive energy to dissipate.
- an explosive event 520 such as an arcing or flashover event, may cause explosive energy or flames to travel from connector opening 310 into expansion chambers 500 .
- the explosive energy may cause a compression of material 510 within expansion chambers 500 , to ameliorate or dissipate the explosive energy in expansion chambers 500 .
- material 510 may decompress and refill expansion chambers 500 , as illustrated in FIG. 5C .
- FIGS. 5A-5C may prevent or minimize damage to connector 100 and/or the surrounding environment resulting from explosive events.
- FIGS. 6A-6D are isometric illustrations of an exemplary connector 100 in various stages of connection.
- female connector 102 is being brought into initial contact with male connector 104 .
- connector pins 138 have been inserted through dead front 110 and dead front 110 has been rotated relative to intermediate housing 108 to align holes 109 in intermediate housing 108 with holes 111 in dead front 110 .
- connector pins 138 , center connector pin 136 , and second housing 132 has been fully inserted into female connector 102 . More specifically, connector pins 138 may be received into contact openings 310 in the first position, as described above, center connector pin 136 may be received into center contact sleeve 122 , and second housing 132 may be received into the gap formed between intermediate housing 108 and first housing 106 .
- guide pins 120 become aligned with an exposed opening in second notched slots 134 in second housing 132 .
- Guide pins 120 may travel axially along notched slots 134 until they reach the first notch in notched slots 134 .
- rotation of female connector 102 relative to male connector 104 may place guide pins 120 into the first position in notched slots 134 and (not shown in FIG. 6C ) notched slots 116 .
- the biasing force created by compression of spring 124 between intermediate housing 108 and first housing 106 causes guide pins 120 to remain in the first position in notched slots 116 and 134 , rather than travel further axially along notched slots 116 and 134 . In this position, a gap remains between female cover 130 and male cover 140 for enabling gases contained within connector 100 to be vented prior to connector 100 being placed into the second position.
- FIG. 6C represents connector 100 in the first connected position, in which female connector 102 is securely attached to male connector 104 , but connector pins 138 are not in close electrical proximity with cup-connectors 126 .
- FIG. 6D illustrates connector 100 in the second connected position, in which female connector 102 is securely attached to male connector 104 and connector pins 138 are electrically connected to cup-connectors 126 .
- female connector 102 is initially moved axially toward male connector 104 . This axial movement causes guide pins 120 to travel along notched slots 134 and 116 and also causes female cover 130 to come into contact with male cover 140 , effectively sealing the environment in which the electric connection is made.
- Female connector 102 is then moved rotationally with respect to male connector 104 . Upon this rotational movement, connector pins 138 may move within contact openings 310 (shown in FIG. 3 ) and into electrical contact with cup-connectors 126 .
- cup-connectors 126 may cause male connector 104 to snap connect with female connector 102 , such that the electrical contact between connector pins 138 and cup-connectors 126 is secure.
- Axial and rotational movement of female connector 102 relative to male connector 104 is represented by directional arrows in FIGS. 6B-6D .
- transition from the first connected position to the second connected position can only occur following full insertion of male connector 104 into female connector 102 , exposure to outside environmental conditions is minimized or reduced by the interrelation of the components of connector 100 , as illustrated in FIG. 2 , thus reducing the likelihood of an explosive accident in the event of arcing or flashover.
- FIGS. 7A and 7B are isometric illustrations of an exemplary connector 100 in various stages of disconnection.
- female connector 102 is moved rotationally with respect to male connector 104 in a direction opposite to the connection direction as referenced by the directional arrow in FIG. 7A .
- the snap connection created between cup-connectors 126 and connector pins 138 may be disengaged by rotating the female connector 102 relative to the male connector 104 with a predetermined amount of torque.
- the C-shape and resilient nature of cup-connectors 126 may cause potential energy to build up as connector pins 138 move out of engagement with cup connectors 126 .
- the potential energy may be released when connector pins 138 pass the narrowest portion of cup-connectors 126 , thereby projecting or snap releasing connector pins 138 from cup connectors 126 .
- female connector 102 is again moved rotationally with respect to male connector 104 , causing guide pins 120 to travel along notched slots 116 and 134 until they reach an end of the first notch.
- Female connector 102 may then be axially removed from male connector 104 , thereby freeing guide pins 120 from notched slot 134 .
- removal of connector pins 138 from female connector 102 allows dead front 110 to snap back to its resting position, by virtue of dead front spring 112 .
- the holes in dead front 110 e.g., holes 111 in FIG. 1
- the holes in intermediate housing 108 e.g., holes 109 in FIG. 1 .
- a user may break electrical contact within connector 100 prior to releasing mechanical attachment between female connector 102 and male connector 104 . This may help to prevent electrical current flashover when connector 100 is detached from a live circuit.
- connectors having four contact pins and a ground pin.
- any suitable number of contact pins may be used, depending on the type of connector being designed or equipment being used.
- connector consistent with the above description may be used in various environments and systems, such as, indoor/outdoor lighting systems, conveyors and light motors, assembly plants, processing plants, pulp and paper facilities, sawmills, steel foundries, etc.
- the above-described connector may be used in hazardous environments, such as oil refineries, gas processing plants, gas pipelines, chemical manufacturing facilities, etc.
Abstract
Description
- This application claims priority under 35. U.S.C. §119, based on U.S. Provisional Patent Application No. 61/218,159 filed Jun. 18, 2009, the disclosure of which is hereby incorporated by reference herein.
- Electrical connectors are used to connect electrical devices to power sources or to join electrical circuits. Electrical connectors generally operate by connecting ground and power terminals of respective connector elements together in a manner that facilitates electrical continuity between the respective elements. In some embodiments, for example, a male connector may be inserted into a corresponding female connector to effect the connection.
- In high voltage environments, additional factors may arise, such as the possibility of arcing or flashover between conducting elements of an electrical connector during connection of disconnection of the connector. These flashover or arcing events may cause injury to users, may ignite flammable or combustible gases in the ambient environment, or may damage equipment.
- Accordingly, connectors in such high voltage or hazardous environments should apply power in a manner that will not damage equipment, and in a manner that provides a safe environment for users.
-
FIG. 1 is an isometric view of an exemplary embodiment of a electrical connector consistent with implementations described herein; -
FIG. 2 is a cross-sectional view of the connector ofFIG. 1 in a connected configuration; -
FIG. 3 is an enlarged, cross-sectional isometric view of the first housing and contact assembly ofFIG. 1 ; -
FIGS. 4A-4E are cross-sectional diagrams illustrating exemplary implementations of the connector ofFIG. 1 ; -
FIGS. 5A-5C are cross-sectional diagrams illustrating additional exemplary implementations of the connector ofFIG. 1 ; -
FIGS. 6A-6D are isometric illustrations of the connector ofFIG. 1 in various stages of connection; and -
FIGS. 7A and 7B are isometric illustrations of the exemplary connector ofFIG. 1 in various stages of disconnection. - The following detailed description refers to the accompanying drawings. The same reference numbers in different drawings may identify the same or similar elements.
- Consistent with implementations described herein, an electrical connector may be provided that minimizes deleterious effects associated with high voltage implementations and/or hazardous environment conditions. For example, in one implementation, an electrical connector may include a male connector and a female connector, with the male connector configured for insertion into the female connector. The female connector may include an access assembly configured to prevent unintentional or undesired access to a contact assembly of the female connector. During connection, conductors in the male connector first bypass a dead front and proceed axially along the female connector to the contact assembly without electrically contacting the conductors in the contact assembly.
- In one implementation, the connector may be placed into a first connected position in which the male connector is securely attached to the female connector, but with the conductors of the male connector not electrically coupled to the female connector. This may be referred to as the connected—OFF position. Additional movement of the female connector and the male connector may bring the conductors into electrical contact and may place the connector into a second connected position, referred to as the connected—ON position.
-
FIG. 1 is an exploded isometric diagram illustrating an exemplaryelectrical connector 100 consistent with embodiments described herein.FIG. 2 is a cross-section diagram ofconnector 100 taken in an axial direction. As illustrated,electrical connector 100 may include afemale connector 102 and amale connector 104.Female connector 102 may further include afirst housing portion 106, anintermediate housing portion 108, adead front 110, a deadfront spring 112, a deadfront pin 114, first notchedslots 116, acontact assembly 118,guide pins 120, acenter contact sleeve 122,spring 124, cup-connectors 126,contacts 128, andfemale cover 130.Male connector 104 may include asecond housing portion 132, secondnotched slots 134, acenter connector pin 136,connector pins 138, and amale cover 140. - As described briefly above, high voltage electrical connectors may be implemented in a variety of environments and applications. Furthermore, arcing or flashover of electricity between the contacts on the male and female sides of the connector may be possible prior to seated contact between the male and female contacts, due to the high voltages. In environments in which flammable or combustion sustaining gases (e.g., a mixture of a explosive gas and oxygen, for example) are present, such flashovers may result in catastrophic damage to personnel, equipment, and/or property. In the manner described in detail below,
connector 100 may include a configuration that provides an insulating and reduced atmospheric environment between male and female contacts at the time of contact connection. - As illustrated in
FIG. 1 ,male connector 104 may includesecond housing 132,center connector pin 136 andconnector pins 138. As described in additional detail below,center connector pin 136 may be configured for insertion into a central hole through the components offemale connector 102. In one implementation,center connector pin 136 may be configured to carry ground or common electrical signals/current.Connector pins 138 may be configured to carry current or electrical signals, such as current for high voltage electrical applications.Connector pins 138, as described more fully below, may be configured for insertion throughdead front 110,intermediate housing 108, andfirst housing 106. Furthermore, following rotation ofmale connector 104 relative tofemale connector 102,connector pins 138 may be configured for insertion into cup-connectors 126. -
Second housing 132 ofmale connector 104 may include notchedslots 134 configured to receiveguide pins 120 connected tofirst housing 106. Travel of guide pins throughnotched slots 134 may guide rotational and axial movement offemale connector 102 relative tomale connector 104 in a predetermined manner, as will be described in additional detail below.Male cover 140 may be formed oversecond housing 132 and may form a protective covering formale connector 104 as well as approximately one half of an enclosed environment forconnector 100 upon connection tofemale connector 102. -
Female connector 102, as described above, may includefirst housing 106,intermediate housing 108, anddead front 110. In one exemplary implementation,first housing 106,intermediate housing 108, anddead front 110 may be substantially cylindrical and may be configured to reside withinfemale cover 130 in a substantially nested manner. More specifically,first housing 106 may include a cavity therein for receivingintermediate housing 108 anddead front 110. - In one implementation, as shown more clearly in
FIG. 2 ,first housing 106,intermediate housing 108, anddead front 110 may be configured such that acylindrical gap 200 is provided between an outer diameter ofintermediate housing 108/dead front 110 and an inner diameter offirst housing 106 whenintermediate housing 108/dead front 110 is mounted axially withinintermediate housing 106. Gap 200 may be of a width suitable for receivingsecond housing 132 ofmale connector 104 during connection ofconnector 100. -
Dead front 110 may be connected axially tointermediate housing 108 via deadfront pin 114. As illustrated,dead front 110 may include a flanged/notched configuration that engages a corresponding notched portion ofintermediate housing 108 such that rotation ofdead front 110 about deadfront pin 114 is enabled within a predetermined range of motion. In addition,intermediate housing 108 anddead front 110 may be further configured to includeholes connector pins 138 inmale connector 104. - In one implementation,
dead front 110 may be spring-loaded with respect tointermediate housing 108, such that the holes indead front 110 are not initially aligned with the holes inintermediate housing 108. In one exemplary embodiment, a central portion ofintermediate housing 108 anddead front 110 may be recessed to receive deadfront spring 112. The biasing force provided by deadfront spring 112 may urgedead front 110 into a first position relative tointermediate housing 108. Rotation ofdead front 110 about deadfront pin 114 may oppose the biasing force of deadfront spring 112 and may causeholes 111 indead front 110 to align withholes 109 inintermediate housing 108. -
Dead front 110 may operate to prevent an unintended or rushed connection ofmale connector 104 tofemale connector 102 in that a user must first insertconnector pins 138 intodead front 110, rotatedead front 110 relative tointermediate housing 108 untilholes 109 align withholes 111, andinsert connector pins 138 further intointermediate housing 108. - In one implementation consistent with implementations described herein, the length and width of
first housing 106,intermediate housing 108, andholes 109 are configured to allow potentially combustible or hot gases to vent away fromcontact assembly 118 during insertion or removal ofconnector pins 138 intofemale connector 102. In other implementations, holes 109 (and/or holes 111) may be filled with a conductive brush material or other assembly for increasing an efficiency of a potential flame path, in the event of an explosion inconnector 100. Additional details relating to the flame path provided inconnector 100 are described below in relation toFIGS. 4A-4E and 5A-5C. -
First housing 106 may be configured to support or otherwise connect to contactassembly 118.FIG. 3 is an enlarged isometric view illustratingfirst housing 106,contact assembly 118,center contact sleeve 122, and cup-connectors 126. As illustrated inFIG. 3 ,first housing 106 may be configured to includecavity 300 for receivingintermediate housing 108 therein, andcontact openings 310 and center spring opening 320 therein which engagingly support cup-connectors 126 andcenter spring 124, respectively. Contactopenings 310 may be further configured to include axial grooves to receiveconnector pins 138 in a first non-connected position. Rotation of connector pins 138 relative to cup-connectors 126 may cause connector pins 138 to move withincontact openings 310 and engage with cup-connectors 126. - Consistent with embodiments described herein, center sleeve opening 320 and
contact openings 310 may be configured to have a minimal volume for containing environmental air and exhaust gases. For example, center sleeve opening 320 may be configured to closely conform to an outside diameter ofcenter contact sleeve 122. Similarly,contact openings 310 may be configured to closely conform in size to cup-connectors 126 and an outside diameter of connector pins 138. In one exemplary implementation, a total volume of space within center spring opening 320 andcontact openings 310 is less than or equal to approximately 10 milliliters (ml). By reducing the volume of gas available withinconnector 310, the likelihood of an explosion occurring during arcing or flashover (or the severity of such an explosion) is significantly reduced. - Furthermore, as illustrated in
FIG. 3 , in one exemplary implementation, cup-connectors 126 may be formed of a resilient, conductive material, having a compressed C-shape as indicated bypinched portion 330, in which an open end of cup-connectors 126 is slightly narrower than a width of connector pins 138. The configuration of cup-connectors 126 may provide a snap-engagement withconnector pins 138 upon rotational engagement between cup-connectors 126 and connector pins 138. More specifically, the compressed C-shape of cup-connectors 126 allows for a build up of potential energy as connector pins 138 traverse and slightly deform the “arms” of cup-connectors 126 and travel towardpinched portion 330 from within the base ofcup connectors 126. Upon reaching the peak ofpinched portion 330, the built up potential energy may be released by projectingconnector pins 138 out of and away from cup-connectors 126, thus providing a snap disconnect releasingconnector pins 138 from cup-connectors 126. - By providing such a snap-engagement between connector pins 138 and cup-
connectors 126, the speed in which a connection may be disengaged (or engaged) is significantly increased over non-snap-engagement implementations. This speed increase further reduces a likelihood of arcing or flashover during connection or disconnection ofconnector 100. -
Center contact sleeve 122 may be configured to receivecenter connector pin 136. Additionally,spring 124 may be positioned aboutcenter contact sleeve 122 within center spring opening 320, such that the biasing force ofspring 124 urgesfirst housing 106 axially away fromintermediate housing 108. As discussed above, the volume of center spring opening 320 as well ascontact openings 310 may be reduced to minimize the likelihood that an explosion will occur or the severity of an explosion in the event of arcing or flashover between connector pins 138 and cup-connectors 126. -
Contacts 128 may be connected to cup-connectors 126 andcenter contact sleeve 122. Eachcontact 128 may be further configured to receive wires or leads that extend throughfemale cover 130. As illustrated inFIG. 2 ,male connector 104 may include similar contacts. - As illustrated in
FIG. 1 ,first housing 106 may be further configured to include guide pins 120. Guide pins 120 may be positioned such that the inwardly extending ends of guide pins 120 are received within first notchedslots 116 inintermediate housing 108. For example, during assembly offemale connector 102,intermediate housing 108 may be inserted intofirst housing 106 prior to insertion of guide pins 120 into corresponding holes infirst housing 106. - The size and location of first notched
slots 116 may be configured to enable both rotational and axial movement ofintermediate housing 108 relative tofirst housing 106 within a predetermined range of motion. As illustrated inFIG. 1 ,intermediate housing 108 may be configured to include a notchedslot 116 allowing two stages of rotational movement, and one stage of axial movement.Second housing 132 inmale connector 104 may be configured to include a similar notchedslot 134. - As will be described in additional detail with respect to
FIGS. 4A-4D , rotational and axial movement of guide pins 120 withinslot 116, as well as corresponding notchedslot 134 inmale connector 104, may facilitate connection offemale connector 102 tomale connector 104 in two distinct positions. In a first position,female connector 102 may be connected tomale connector 104, but connector pins 138 are not electrically coupled to cup-connectors 126. This may be referred to as the connected—OFF position. In a second position, connector pins 138 may be moved into electrical engagement with cup-connectors 126. This may be referred to as the connected—ON position. As briefly discussed above, the shape of cup-connectors 126 may effectively secure connector pins 138 within cup-connectors 126 upon movement ofconnectors - As illustrated in
FIG. 2 , upon connection offemale connector 102 tomale connector 104,second housing 132 may become inserted in the gap formed betweenintermediate housing 108 andfirst housing 106.Connector 100 may be further configured such that guide pins 120 restrain relative movement betweenfirst housing 106,intermediate housing 108, andsecond housing 132. Becausecontact assembly 118 is fixed relative tofirst housing 106 andconnector pins 138 are fixed relative tosecond housing 132, rotation betweenfirst housing 106 andsecond housing 132 effectively brings connector pins 138 into electrical contact with cup-connectors 126. However, because electrical contact is only possible following initial insertion ofmale connector 104 intofemale connector 102 in the first (e.g., non connected) position,female cover 130 andmale cover 140 may form a contained environment sufficient to minimize an exposure to potentially volatile environmental conditions prior to electrical contact or proximity between connector pins 138 and cup-connectors 126. - As will be discussed below in relation to
FIGS. 4A-4E and 5A-5C, interaction of components withinconnector 100 may provide a flame path for venting of a flame or explosion in the event of an explosion withinconnector 100. More specifically, elements ofintermediate housing 108,female cover 130, and/ormale cover 140 may be configured to provide for the venting or extinguishing of any such flame without destroyingconnector 100 or damaging the surrounding environment or personnel. - Furthermore,
spring 124 may provide an opposing force between guide pins 120 affixed tofirst housing 106 and notchedslots 116 inintermediate housing 108. This biasing force may be suitable for preventing or minimizing unintended movement of guide pins 120 relative to notchedslots 116 through the positioning and size of the notches in notchedslots 116. -
Female cover 130 may be formed overfirst housing 106 and may form a protective covering forfemale connector 104 as well as approximately one half of the enclosed environment forconnector 100 upon connection tomale connector 102. In one exemplary implementation,female cover 130 and/ormale cover 140 may be formed of a plastic, rubber, or elastomeric material that provides both a high friction, easily grippable surface, in additional to protective insulative properties. In other implementations,female cover 130 andmale cover 140 may include a textured or ridges surface to further enhance secure handling and connection ofconnector 100. -
FIGS. 4A-4E are cross-sectional diagrams illustrating exemplary implementations of theconnector 100. InFIG. 4A , an explosion or spark 400 at an interface betweenconnector pin 138 and cup-connector 126 may travel along aflame path 410 provided for inconnector 100. As shown,flame path 400 may include interfacing surfaces betweenfirst housing 106 and intermediate housing 108 {circle around (1)}, interfacing surfaces betweensecond housing 132 and first housing 106 {circle around (2)}, and interfacing surfaces betweenfirst housing 106 and male cover 140 {circle around (3)}. As illustrated, an explosion or spark may travel alongflame path 410 and may vent fromconnector 100 at the interface betweenmale cover 140 andfemale cover 130. By providing an exhaustible flame path for enabling the release of explosive energy or flames fromconnector 100,connector 100 may be capable of operating safely in hazardous environments. -
FIG. 4B illustrates another exemplary implementation of the interface betweenmale cover 140,female cover 130, andfirst housing 106. As illustrated inFIG. 4B , agap 415 may be provided betweenmale cover 140 andfemale cover 130.Gap 415 may be suitably sized to efficiently enable release of explosive energy or flames fromflame path 410 in the event of arcing or flashover withinconnector 100, as described above in relation toFIG. 4A . -
FIGS. 4C and 4D illustrates another exemplary implementation of the interface betweenmale cover 140,female cover 130, andfirst housing 106. As illustrated inFIGS. 4C and 4D , amale cover 140 may be provided with a hingedportion 420 or flap proximate to the interface withfemale cover 130. As illustrated inFIG. 4D , in the event of an explosion or flame withinflame path 410, hingedportion 420 may open or deform to allow the explosive energy, flames, and/or hot gases to exhaust fromconnector 100. AlthoughFIGS. 4C and 4D depict hingedportion 420 as being part ofmale cover 140, hinged portion may also be provided infemale cover 140, or in bothmale cover 140 andfemale cover 130. -
FIG. 4E illustrates yet another exemplary implementation of the interface betweenmale cover 140,female cover 130, andfirst housing 106. As illustrated inFIG. 4E ,male cover 140 andfemale cover 130 may be configured to overlap. For example,male cover 140 may be provided with anenlarged portion 425 configured to receivefemale cover 130 in an overlapping manner. In some implementations,female cover 130 may be configured to interlock withenlarged portion 425 to further securefemale connector 102 tomale connector 104 during connection. - In the event of an explosion or flame within
flame path 410,flame path 410 may continue along the interface betweenenlarged portion 420 andfemale connector 130 to allow the explosive energy, flames, and/or hot gases to exhaust fromconnector 100.Enlarged portion 425 may be suitably sized to efficiently enable release of explosive energy or flames fromflame path 410 in the event of arcing or flashover withinconnector 100. -
FIGS. 5A-5C are cross-sectional diagrams illustrating additional exemplary implementations ofconnector 100. As illustrated inFIG. 5A ,intermediate housing 108 may include one ormore expansion chambers 500 for receiving explosive energy resulting from an explosion or spark experienced at an interface betweenconnector pin 138 and cup-connector. For example, each interface between aconnector pin 138 and a cup-connector 126 may be connected to arespective expansion chamber 500, e.g., viaconductor opening 310. In one implementation, as illustrated inFIGS. 5A-5C ,expansion chambers 500 may include a resilient and/orcompressible material 510 configured to compress and absorb explosive energy in the event of an explosion or spark. Compression ofmaterial 510 also opens up a volume ofexpansions chamber 500 thereby allowing explosive energy to dissipate. - As illustrated in
FIG. 5A , in an initial, uncompressed state,material 510 substantially fills a volume of eachexpansion chamber 500. However, as illustrated inFIG. 5B , anexplosive event 520, such as an arcing or flashover event, may cause explosive energy or flames to travel fromconnector opening 310 intoexpansion chambers 500. - As illustrated in
FIG. 5B , the explosive energy may cause a compression ofmaterial 510 withinexpansion chambers 500, to ameliorate or dissipate the explosive energy inexpansion chambers 500. Upon dissipation of the explosive energy,material 510 may decompress and refillexpansion chambers 500, as illustrated inFIG. 5C . - By providing an expansion chamber having a compressible material there, the embodiment of
FIGS. 5A-5C may prevent or minimize damage toconnector 100 and/or the surrounding environment resulting from explosive events. -
FIGS. 6A-6D are isometric illustrations of anexemplary connector 100 in various stages of connection. InFIG. 6A ,female connector 102 is being brought into initial contact withmale connector 104. InFIG. 6B , connector pins 138 have been inserted throughdead front 110 anddead front 110 has been rotated relative tointermediate housing 108 to alignholes 109 inintermediate housing 108 withholes 111 indead front 110. - In
FIG. 6C , connector pins 138,center connector pin 136, andsecond housing 132 has been fully inserted intofemale connector 102. More specifically, connector pins 138 may be received intocontact openings 310 in the first position, as described above,center connector pin 136 may be received intocenter contact sleeve 122, andsecond housing 132 may be received into the gap formed betweenintermediate housing 108 andfirst housing 106. - Moreover, when connector pins 138 are inserted through
intermediate housing 108, guide pins 120 become aligned with an exposed opening in second notchedslots 134 insecond housing 132. Guide pins 120 may travel axially along notchedslots 134 until they reach the first notch in notchedslots 134. Following axial insertion, rotation offemale connector 102 relative tomale connector 104 may place guide pins 120 into the first position in notchedslots 134 and (not shown inFIG. 6C ) notchedslots 116. - As described above, the biasing force created by compression of
spring 124 betweenintermediate housing 108 andfirst housing 106 causes guidepins 120 to remain in the first position in notchedslots slots female cover 130 andmale cover 140 for enabling gases contained withinconnector 100 to be vented prior toconnector 100 being placed into the second position. -
FIG. 6C representsconnector 100 in the first connected position, in whichfemale connector 102 is securely attached tomale connector 104, but connector pins 138 are not in close electrical proximity with cup-connectors 126. -
FIG. 6D illustratesconnector 100 in the second connected position, in whichfemale connector 102 is securely attached tomale connector 104 andconnector pins 138 are electrically connected to cup-connectors 126. To enter the second position,female connector 102 is initially moved axially towardmale connector 104. This axial movement causes guidepins 120 to travel along notchedslots female cover 130 to come into contact withmale cover 140, effectively sealing the environment in which the electric connection is made.Female connector 102 is then moved rotationally with respect tomale connector 104. Upon this rotational movement, connector pins 138 may move within contact openings 310 (shown inFIG. 3 ) and into electrical contact with cup-connectors 126. As described briefly above, the shape of cup-connectors 126 may causemale connector 104 to snap connect withfemale connector 102, such that the electrical contact between connector pins 138 and cup-connectors 126 is secure. Axial and rotational movement offemale connector 102 relative tomale connector 104 is represented by directional arrows inFIGS. 6B-6D . - Because transition from the first connected position to the second connected position can only occur following full insertion of
male connector 104 intofemale connector 102, exposure to outside environmental conditions is minimized or reduced by the interrelation of the components ofconnector 100, as illustrated inFIG. 2 , thus reducing the likelihood of an explosive accident in the event of arcing or flashover. -
FIGS. 7A and 7B are isometric illustrations of anexemplary connector 100 in various stages of disconnection. InFIG. 7A ,female connector 102 is moved rotationally with respect tomale connector 104 in a direction opposite to the connection direction as referenced by the directional arrow inFIG. 7A . In one exemplary embodiment, the snap connection created between cup-connectors 126 and connector pins 138 may be disengaged by rotating thefemale connector 102 relative to themale connector 104 with a predetermined amount of torque. As described above, the C-shape and resilient nature of cup-connectors 126 may cause potential energy to build up as connector pins 138 move out of engagement withcup connectors 126. The potential energy may be released when connector pins 138 pass the narrowest portion of cup-connectors 126, thereby projecting or snap releasingconnector pins 138 fromcup connectors 126. - Continued rotational movement of
female connector 102 relative tomale connector 104 causes guidepins 120 to travel along notchedslots spring 124 then causesfemale connector 102 to move axially away frommale connector 104 and back to the first connected position. - As illustrated in
FIG. 7B ,female connector 102 is again moved rotationally with respect tomale connector 104, causing guide pins 120 to travel along notchedslots Female connector 102 may then be axially removed frommale connector 104, thereby freeing guide pins 120 from notchedslot 134. Although not explicitly illustrated inFIG. 7B , removal of connector pins 138 fromfemale connector 102 allowsdead front 110 to snap back to its resting position, by virtue of deadfront spring 112. In this position, the holes in dead front 110 (e.g., holes 111 inFIG. 1 ) are no longer axially aligned with the holes in intermediate housing 108 (e.g., holes 109 inFIG. 1 ). In this manner, a user may break electrical contact withinconnector 100 prior to releasing mechanical attachment betweenfemale connector 102 andmale connector 104. This may help to prevent electrical current flashover whenconnector 100 is detached from a live circuit. - The foregoing description of exemplary implementations provides illustration and description, but is not intended to be exhaustive or to limit the embodiments described herein to the precise form disclosed. Modifications and variations are possible in light of the above teachings or may be acquired from practice of the embodiments.
- For example, various features have been mainly described above with respect to a electrical connectors having four contact pins and a ground pin. In other implementations, any suitable number of contact pins may be used, depending on the type of connector being designed or equipment being used. In some implementations, connector consistent with the above description may be used in various environments and systems, such as, indoor/outdoor lighting systems, conveyors and light motors, assembly plants, processing plants, pulp and paper facilities, sawmills, steel foundries, etc. In addition, the above-described connector may be used in hazardous environments, such as oil refineries, gas processing plants, gas pipelines, chemical manufacturing facilities, etc.
- Although the invention has been described in detail above, it is expressly understood that it will be apparent to persons skilled in the relevant art that the invention may be modified without departing from the spirit of the invention. Various changes of form, design, or arrangement may be made to the invention without departing from the spirit and scope of the invention. Therefore, the above-mentioned description is to be considered exemplary, rather than limiting, and the true scope of the invention is that defined in the following claims.
- No element, act, or instruction used in the description of the present application should be construed as critical or essential to the invention unless explicitly described as such. Also, as used herein, the article “a” is intended to include one or more items. Where only one item is intended, the term “one” or similar language is used. Further, the phrase “based on” is intended to mean “based, at least in part, on” unless explicitly stated otherwise.
Claims (28)
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US12/817,491 US8328573B2 (en) | 2009-06-18 | 2010-06-17 | Electrical connector |
CA2707798A CA2707798C (en) | 2009-06-18 | 2010-06-18 | Electrical connector |
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US21815909P | 2009-06-18 | 2009-06-18 | |
US12/817,491 US8328573B2 (en) | 2009-06-18 | 2010-06-17 | Electrical connector |
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US20100323542A1 true US20100323542A1 (en) | 2010-12-23 |
US8328573B2 US8328573B2 (en) | 2012-12-11 |
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US20150130486A1 (en) * | 2013-11-13 | 2015-05-14 | Hamilton Sundstrand Corporation | Electrical connector pin cover |
US10122123B1 (en) * | 2017-07-07 | 2018-11-06 | International Business Machines Corporation | Electrical arc protection using a rotational shield |
FR3068180A1 (en) * | 2017-06-26 | 2018-12-28 | Societe D'exploitation Des Procedes Marechal | ELECTRICAL CONNECTING BASE COMPRISING A CONNECTING MOBILE ELEMENT, ADDITIONAL ELECTRICAL CONNECTION BASE, AND ASSEMBLY COMPRISING SUCH BASES |
US10229806B2 (en) | 2016-11-01 | 2019-03-12 | International Business Machines Corporation | Electrical arc protection using a trip jumper |
US10230193B2 (en) | 2016-11-01 | 2019-03-12 | International Business Machines Corporation | Electrical arc protection using a trip contact |
US11276951B2 (en) * | 2018-01-12 | 2022-03-15 | Marechal Electric | Socket-outlet equipped with a disc and a shutter |
GB2560227B (en) * | 2016-12-29 | 2022-06-01 | Itt Mfg Enterprises Llc | Flame-proof connectors |
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US10229806B2 (en) | 2016-11-01 | 2019-03-12 | International Business Machines Corporation | Electrical arc protection using a trip jumper |
US10230193B2 (en) | 2016-11-01 | 2019-03-12 | International Business Machines Corporation | Electrical arc protection using a trip contact |
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US11489297B2 (en) | 2017-06-26 | 2022-11-01 | Marechal Electric | Electrical connection mount comprising a movable connection element, complementary electrical connection mount, and assembly comprising such mounts |
US10122123B1 (en) * | 2017-07-07 | 2018-11-06 | International Business Machines Corporation | Electrical arc protection using a rotational shield |
US11276951B2 (en) * | 2018-01-12 | 2022-03-15 | Marechal Electric | Socket-outlet equipped with a disc and a shutter |
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